The International journal of analytical and experimental modal analysis ISSN NO:0886-9367

PERFORMANCE OF A FINNED-TUBE EVAPORATOR OPTIMIZED FOR

DIFFERENT MIXED REFRIGERANTS ON SYSTEM EFFICIENCY
Vikranth1 Dr. Naveen Kumar2 M Tech,Ph D Dr. NT Ravikumar3 M Tech,Ph D
1
M.tech student , Department of mechanical engineering, Siddhartha Institute Of Technology Sciences & Sciences
Hyderabad, Telangana 50130.
2
Professor, Department of mechanical engineering, Siddhartha Institute Of Technology Sciences & Sciences
Hyderabad, Telangana 50130.
3
Professor, Department of mechanical engineering, Siddhartha Institute Of Technology Sciences & Sciences.
Hyderabad, Telangana 50130.

Abstract :An evaporator is use in an air-conditioning
system or refrigeration system to allow a compressed
cooling chemical, such as Freon or R-134A, to
evaporate from liquid to gas while enthralling heat in
the process. It is also use to remove water or other
liquids from mixtures. In this paper, The isotropic
mixture of R134A & R160 we are taken, R134A As a
base fluid mixing with R160 with concentrations of
0%, 20%, 40%, 60%, 80% and 100% and it is used in
a Refrigeration unit with different flow rates by
fixing the other input parameters such as a pressure
and temperatures are constant in evaporator.
The fin tube evaporator is modeled in 3D modeling
software CATIA. The fins considered are rectangular
fin, Hexagonal Fin and circular fin. The mass flow
rate and heat transfer rate are analyzed by using CFD
technique in ANSYS software. Thermal analysis
conducted on evaporator with different materials
such as aluminum alloy 7475, copper and brass.
Key words: CFD, Thermal, CATIA, Hexagonal Fin,
aluminum alloy 7475.
1. Introduction
An evaporator is a device in a process used to turn
the liquid form of a chemical substance such as water
into its gaseous-form/vapor. The liquid is evaporated,
or vaporized, into a gas form of the targeted
substance in that process. One kind of evaporator is a
kind of radiator coil used in a closed compressor
driven circulation of a liquid coolant. That is called
an air-conditioning system (A/C) or refrigeration
system to allow a compressed cooling chemical, such
as R-22 (Freon) or R-410A, to evaporate/vaporize
from liquid to gas within the system while absorbing
heat from the enclosed cooled area, for example a
refrigerator or rooms indoors, in the process. This
works in the closed A/C or refrigeration system with
a condenser radiator coil that exchanges the heat
from the coolant, such as into the ambient
environment. A different kind of evaporator can be
used for heating and possibly boiling a product
containing a liquid to cause the liquid to evaporate
from the product.
The appropriate process can be used to remove water
or other liquids from liquid based mixtures. The
process of evaporation is widely used to concentrate
liquid foods, such as soup or make concentrated milk
called "condensed milk" done by evaporating water
from the milk. In the concentration process, the goal
of evaporation is to vaporize most of the water from a
solution which contains the desired product
1.1 Finned Evaporators
In this type of evaporator the outer surface area is
surrounded by thin metallic plates called fins. Fins
are thin metallic plates, usually aluminum or copper,
securely attached or banded to the evaporator tubes,
with bare tube evaporators. These fins increase the
heat transfer efficiency of the evaporator. Finned
evaporators are used in air cooling application.
Fig :1 Finned Evaporator
1.2 Literature Survey
In the paper by Jader R. Barbosa, etal[1], the purpose
is to assess some aspects of the design of evaporators
for household refrigeration appliances using
Computational Fluid Dynamics (CFD). The
evaporators under study are tube-fin 'no-frost' heat
exchangers with forced convection on the air-side
and a staggered tube configuration. The calculation
methodology was verified against experimental data
for the heat transfer rate, thermal conductance and
pressure drop obtained for two evaporators with
different geometries.
In the paper by Zine Aidoun, etal[2], Almost all
forced convection air coolers use finned tubes. Coils
have in this way become established as the heat

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The International journal of analytical and experimental modal analysis
transfer workhorse of the refrigeration industry,
because of their high area density, their relatively low
cost, and the excellent thermo physical properties of
copper and aluminum, which are their principal
construction materials. Compact coils are needed to
facilitate the repackaging of a number of types of air
conditioning and refrigeration equipment: a reduced
volume effectively enables a new approach to be
made to the modular design and a route towards
improving performance and size is through
appropriate selection of refrigerants, heat transfer
enhancement of primary and secondary surfaces
through advanced fin design and circuit
configurations.
In the paper by Kiran B. Parikh, etal[3], an
Evaporator is the Main component of Air-
conditioning system. An evaporator is mainly used in
different refrigeration and air-conditioning
applications in food and beverage industry, in the
pharmaceutical industry etc. An evaporator in air
conditioning system is used to evaporate liquid and
convert in to vapour while absorbing heat in the
processes, this paper presents the study of the fin tube
type Evaporator; An Experimental data were
collected from the IC ICE MAKE Company. After
collecting data of fin tube evaporator model is
prepared using solid works. At the end, FEA analysis
is carried out on it using ANSYS CFX, The result of
analysis is compared with Experimental result. 3.7%
variation found in both results.
In the paper by Carles OLIET, etal[4], summarizes
the research work carried out by the authors on
domestic refrigerator no-frost evaporators. It includes
an explanation of the experimental unit that is
currently being constructed to test isobutane fin-and-
tube evaporators, together with a short description of
the numerical tools developed. The first preliminary
experimental results using single-phase coolants are
then given together with their numerical counterparts.
The numerical results are presented in detail in order
to both complementing the experimental information
obtained, and to show its potential as an analysis and
design tool.
In the paper by Shun Ching Lee [5], behavior of
cryogenic nitrogen in a room-temperature evaporator
six meters long is analyzed. Trapezoid fins are
employed to enhance the heat flux supplied by the
environment. The steady-state governing equations
specified by the mixed parameters are derived from
the conservations of momentum and energy. The
initial value problem is solved by space integration.
The fixed ambient conditions are confirmed by way
of the meltback effect. An integrated model is
utilized to analyze the convective effect of two-phase
flow, which dominates the evaporation behavior.
Another integrated model is employed to determine
Volume XII, Issue XII, December/2020
ISSN NO:0886-9367
the total heat flux from the environment to the wet
surface of the evaporator.
Domanski, etal[6], a comparable evaluation of R600a
(isobutane), R290 (propane), R134a, R22, R410A,
and R32 in an optimized finned-tube evaporator, and
analyzes the impact of evaporator effects on the
system coefficient of performance (COP). The study
relied on a detailed evaporator model derived from
NIST’s EVAP-COND simulation package and used
the ISHED1 scheme employing a non-Darwinian
learnable evolution model for circuitry optimization.
In the process, 4500 circuitry designs were generated
and evaluated for each refrigerant.
2. MATERIALS AND METHODS
2.1 Aluminum alloy 7475
Aluminum alloys have high electrical conductivity
and strong corrosion resistance characteristics. These
alloys are good low-temperature alloys. They gain
strength when exposed to subzero temperatures and
lose strength when exposed to high temperatures
2.2 Copper
Copper is a good conductor of heat. This means that
if you heat one end of a piece of copper, the other end
will quickly reach the same temperature. Most metals
are pretty good conductors; however, apart from
silver, copper is the best.
2.3 Brass
Brass is an alloy of copper and zinc, in proportions
which can be varied to achieve varying mechanical
and electrical properties. It is a substitutional alloy:
atoms of the two constituents may replace each other
within the same crystal structure.Brass is similar to
bronze, another alloy containing copper, with tin in
place of zinc
Table: 1 thermal properties
Materials Thermal Specific Density
conductivity heat (kg/m3)
(w/m k) (j/kg-k)
Aluminum 163 880 2705
alloy 7475
Copper 385 385 8960
Brass 109 380 8587
2.4 Refrigerants
R134a is also known as Tetra fluoroethane
(CF3CH2F) from the family of HFC refrigerant.
With the discovery of the damaging effect of CFCs
and HCFCs refrigerants to the ozone layer, the HFC
family of refrigerant has been widely used as their
replacement. It is now being used as a replacement
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for R-12 CFC refrigerant in the area of centrifugal, behavior of the evaporator by performing the finite
rotary screw, scroll and reciprocating compressors. It element analysis.3D modeling software
is safe for normal handling as it is non-toxic, non- CATIA was used for designing and analysis software
flammable and non-corrosive. (ANSYS) was used for CFD and thermal analysis.
Properties Modeling and analysis
Properties R-134a CATIA PARAMETRIC SOFTWARE
Boiling Point -14.9°F or -26.1°C Computer Aided Design (CAD) is the use of
Auto-Ignition 1418°F or 770°C computer software to design a product or an object.
Temperature Computer Aided Manufacturing (CAM) is the use of
Ozone Depletion Level 0 computer software and hardware to plan, manage and
control the operations of a manufacturing plant.
Solubility In Water 0.11% by weight at 77°F
Computer Aided Engineering is the use of computer
or 25°C
software to solve engineering problems and analyze
Critical Temperature 252°F or 122°C
products created using CAD.CATIA is an acronym
Cylinder Color Code Light Blue for Computer Aided Three-dimensional Interactive
Global Warming Potential 1200 Application. It is one of the leading 3D software used
(GWP) by organizations in multiple industries ranging from
aerospace, automobile to consumer products. CATIA
R160 is a Chloroethane, commonly known by its old is a multi platform 3D software suite developed by
name ethyl chloride, is a chemical compound with Dassault Systems, encompassing CAD, CAM as well
chemical formula CH3CH2Cl, once widely used in as CAE.
producing tetraethyllead, a gasoline additive. It is a ANSYS
colorless, flammable gas or refrigerated liquid with a The governing equations in ANSYS Forte follow
faintly sweet odor mainly the Continuity equation, Momentum equation
(Navier Stokes equation) and Energy equation to
solve computational fluid dynamics problem.
Properties R-160 The conservation equation for species is given by :
𝜕𝜌
Density 0.8898 g/cm3 (25 °C) 𝑘 + ∇ ∙ 𝜌𝑘𝑢 = ∇ ∙ 𝜌𝐷𝑇∇𝜌𝑘𝜌 + 𝜌𝑘𝑐 + 𝜌𝑘𝑠𝑘 =
𝜕𝑡
Melting point −138.7 °C (−217.7 °F; 1, ⋯ , 𝐾 (1)
134.5 K) Where: 𝜌 is the density, subscript 𝑘 is the species
index, 𝐾 is the total number of species, 𝑢 is the flow
Boiling point 12.27 °C (54.09 °F;
velocity vector. Application of Fick’s Law of
285.42 K)
diffusion results in a mixture-averaged turbulent
0.574 g/100 mL (20 °C
Solubility in water diffusion coefficient DT. 𝜌𝑘𝑐 and 𝜌𝑘 s are source
terms due to chemical reactions and spray
Solubility in ethanol 48.3 g/100 g (21 °C) evaporation, respectively. The summation of
Equation 1 over all species gives the continuity
Vapor pressure 134.6 kPa (20 °C equation for the total fluid
𝜕𝜌
Viscosity 0.279 cP (10 °C +∇∙ 𝜌∙𝑢 =𝜌
𝜕𝑡
(2)
Steady-state thermal analyses calculate the effects of
METHODOLOGY
steady thermal loads on a system or component.
 Study the literature review.
Users often perform a steady-state analysis before
 Create the 3D model of evaporator with help
doing a transient thermal analysis, to help establish
of CATIA parametric software.
initial conditions. A steady-state analysis also can be
 Selection of fluids, R134A as a base fluid the last step of a transient thermal analysis;
mixing with R160. performed after all transient effects have diminished.
 Theoretical calculations for thermo physical ANSYS can be used to determine temperatures,
properties thermal gradients, heat flow rates, and heat fluxes in
 Perform CFD and thermal analysis on the an object that are caused by thermal loads that do not
evaporator assembly for thermal loads. vary over time.
PROBLEM DESCRIPTION: Computational fluid dynamics, usually abbreviated as
The objective of this project is to make a 3D model CFD, is a branch of fluid mechanics that uses
of the evaporator and study the CFD and thermal numerical methods and algorithms to solve and

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The International journal of analytical and experimental modal analysis ISSN NO:0886-9367

analyze problems that involve fluid flows. Computers

are used to perform the calculations required to
simulate the interaction of liquids and gases with
surfaces defined by boundary conditions. With high-
speed supercomputers, better solutions can be
achieved. Ongoing research yields software that
improves the accuracy and speed of complex
simulation scenarios such as transonic or turbulent
flows. Initial experimental validation of such Fig: 3 Rectangular finned tube evaporator
software is performed using a wind tunnel with the
final validation coming in full-scale testing, e.g.
flight tests.

Thermo physical properties Calculations

ρnf= Density of nano fluid (kg/m3)
ρs= Density of solid material (kg/m3)
ρb = Density of fluid material (base) (kg/m3)
ϕ = Volume fraction Fig: 4 Hexagonal finned tube evaporator
Cbw = Specific heat of fluid material (base) (j/kg-k) RESULTS AND DISCUSSION
Cps = Specific heat of solid material (j/kg-k) CFD Analysis of Finned Tube Evaporator
µw = Viscosity of fluid (water) (kg/m-s) Rectangular Fins
µnf = Viscosity of Nano fluid (kg/m-s)
Kb= Thermal conductivity of fluid material (base) (W/m-k)
Ks = Thermal conductivity of solid material (W/m-k)

Density Of Nano Fluid

ρnf= ϕ×ρs + [(1-ϕ) × ρw]

Fig: imported model
Specific Heat Of Fluid
ϕ×ρs×Cps + 1−ϕ (ρw ×Cpw )
Cpnf = ϕ×ρs+(1−ϕ)×ρw Volume Density Specific Thermal Viscosity
Viscosity of Fluid fraction 3
(kg/m ) heat conductivity (kg/m-s)
µnf =µw (1+2.5ϕ) (ɸ) (j/kg-k) (w/m-k)
Thermal Conductivity Of Fluid
Ks +2Kw +2 Ks −Kw 1+β ³×ϕ 0.2 1091.56 1031.312 0.00033 0.00560
Knf = × kw
𝐾𝑠+2𝐾𝑤 − 𝐾𝑠−𝐾𝑤 1+𝛽 ³×𝜙 0.4 1048.92 1252.884 0.00044 0.00455
Table: 2 Thermo Physical Properties
0.6 1006.28 1027.508 0.00055 0.00420

0.8 963.64 1025.311 0.00066 0.00402

3d Models of Evaporator

Fig : meshed model

Fluid At volume fraction-0.4%
Fig: 2 circular finned tube evaporator

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Fig: pressure counters Fig: Heat Transfer Coefficient

Mass Flow Rate

Fig: Heat Transfer Coefficient

Mass Flow Rate

Heat Transfer Rate

Heat Transfer Rate

THERMAL ANALYSIS OF FINNED TUBE

EVAPORATOR
Material: copper
Case –hexagonal Fins Case 1-Rectangular Fins
Temperature

Fig: imported model

Heat flux

Fig: pressure counters

Case 2-hexagonal fin
Temperature

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Heat flux

Graphs
Plot: 1 pressure versus volume fractions of fluid

RESULT TABELS
Table: CFD analysis results

Plot: 2 Velocity versus volume fractions of fluid

Plot: 3Heat transfer coefficient versus volume

fractions of fluid

Thermal analysis results

Fin Materials Temperature Heat flux
geometry (oC) (W/mm2)

Rectangular Aluminum 20.803 1.0193

alloy
7475
Copper 14.412 1.9435
Brass 21.428 0.8404
Circular Aluminum 5.62 0.98626
alloy
7475 Plot: 4 mass flow rate versus volume fractions of
fluid
Copper 8.0818 1.531
Brass 9.002 0.8424
Hexagonal Aluminum 15.162 0.971
alloy
7475
Copper 2.382 1.676
Brass 17.459 0.824

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Plot: 5 heat transfer rate versus volume fractions of
fluid
Plot: 5 heat flux versus volume fractions of fluid
CONCLUSION
CFD analysis is done by varying the volume fractions
as a 0.2, 0.4, 0.6 and 0.8% of R 160 fluid and base
fluid as R134a at different fin geometries (circular,
rectangular and hexagonal).CFD and thermal analysis
is done in ANSYS.
By observing the CFD analysis results, heat transfer
coefficient increases the increasing the volume
fraction of fluid and heat transfer rate, mass flow rate
is more for rectangular fin at 0.4 % volume fraction.
By observing the thermal analysis results, the heat
flux is more for copper material at rectangular fin
than circular and hexagonal fins.
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So we can conclude that aluminum is the better
material for fin tube evaporator because light weight
than brass and copper.
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